Methods and apparatus for operating production facilities

ABSTRACT

A method and apparatus for operating a production system that includes a plurality of production facilities is provided. The method includes receiving, in real-time, for each facility, cost data for a first resource used by each respective facility to produce an output, receiving, in real-time, for each facility, cost data for a second resource used by each respective facility to produce the output, determining, in real-time; an automated incremental cost curve for the system based on a level of production of each facility and the received resource cost data, and determining a production output target for each production facility to achieve an optimum production system output based on the real-time incremental cost curves. The system includes at least one production facility that includes a software code segment programmed to determine, in real-time, an incremental cost of a first resource based on a level of production of each respective facility.

BACKGROUND OF THE INVENTION

[0001] This invention relates generally to the control of productionfacilities, and more particularly to a system for optimizing the outputof a system of production facilities.

[0002] At least some known production systems include a plurality ofproduction facilities that operate in parallel such that each facilityreceives production resources independently of the other facilities inthe system. The output of such production facilities may be linked via acommon stream of commerce. For example, an electric utility may have aplurality of independent generating facilities located throughout aterritory. Each generating facility may receive fuel from independentsuppliers and the output of each facility may be coupled through acommon transmission system or grid, such that, if one facility becameunable to deliver a required output to the grid, another facility shouldbe able to increase its output to accommodate for the shortfall. Thisprocess is nearly transparent to users or customers of the grid.

[0003] Each facility may have operating characteristics that aredifferent than each other facility in the production system, such thatthe operating efficiency of each facility may be different than theoperating efficiency of every other facility. Operating efficiency maybe defined in terms of the utilization of resources per unit of output.For example, within an electric utility, although several resources,such as fuel, labor, emissions allowances, and water may be used togenerate power, improving the efficiency of each facility's use of fuelmay cause the largest impact to the economical generation of electricityas a whole. Ideally, each facility may be operated individually tofacilitate maximizing the facility efficiency, or to generate theproduction output using the least amount of resources. However, toincrease the operating efficiency of the production system, eachindividual facility may be operated to facilitate maximizing theefficiency of the production system, which may not be the same asoperating each facility at its individual optimum efficiency level.

[0004] Accordingly, to facilitate maximizing the efficiency of theproduction system, at least some known power production systems attemptto dispatch power generating facilities in an economical manner byadjusting load on each facility to facilitate attaining the highestsystem-wide efficiency possible. Such systems utilize testing methods todetermine a cost of resource inputs required at each level of productionoutput of each facility to develop an economic dispatch curve for theproduction system.

[0005] Testing of facility components is periodically conducted undervarious conditions to develop individual component efficiency curves,which are used to develop the economic dispatch curves. Morespecifically, testing of the production facility is conductedperiodically to verify the correctness of component efficiency tooverall facility efficiency assumptions. However, due to the periodicscheduling of efficiency testing, the validity of the testing resultsand the assumptions underlying the efficiency calculations may only bereliable for a short time period until the tests are run again. Forexample, various causes of uncertainty may undesirably introducemisleading data into calculations relied upon to achieve optimalproduction system dispatch, which as a result may produce inefficientsystem operations. Testing components and testing the facility atshortened intervals may improve economic dispatch curves, but testing islabor intensive may require operational limits on the facility duringthe time period the testing is taking place.

BRIEF DESCRIPTION OF THE INVENTION

[0006] In one aspect, a method for operating a production system thatincludes a plurality of production facilities is provided. The methodincludes receiving, in real-time, for each facility, cost data for afirst resource used by each respective facility to produce an output,receiving, in real-time, for each facility, cost data for a secondresource used by each respective facility to produce the output,determining, in real-time; an automated incremental cost curve for thesystem based on a level of production for each facility and the receivedresource cost data, and determining a production output target for eachproduction facility to achieve an optimum production system output basedon the real-time incremental cost curves.

[0007] In another aspect, a production system for producing an output isprovided. The system includes at least one production facility thatincludes a first resource receiving system, and a second resourceconfigured to control and utilize the first resource in a productionprocess, and a computer system that includes a software code segmentprogrammed to determine, in real-time, an incremental cost of the firstresource based on a level of production of the facility.

[0008] In yet another aspect, a software code segment for controlling acomputer to determine, in real-time, an incremental cost of operating aplurality of production facilities is provided. The determination isbased on a first resource input and a second resource utilization of thefirst resource, and the incremental cost is based on a level ofproduction of each facility. The segment includes a fuel tracking moduleprogrammed for tracking at least one of real-time fuel cost, real-timefuel flow, and real time fuel quality for each facility, a processcomponent tracking module for modeling facility components to generatereal-time heat rate curves for each facility, and a dispatch decisionmodule programmed to receive inputs from at least one of said fueltracking module, said process component tracking module, and saiddispatch decision module configured to generate real-time systemdispatch cost curves.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a schematic diagram of an exemplary production system;

[0010]FIG. 2 is a detailed schematic of an exemplary production facilitythat may be used with the system shown in FIG. 1;

[0011]FIG. 3 is a simplified block diagram of a real-time productionsystem economic dispatch system;

[0012]FIG. 4 is an expanded version block diagram of an exemplaryarchitecture of a server system of the real-time production systemeconomic dispatch system shown in FIG. 3;

[0013]FIG. 5 is a flow chart illustrating an exemplary method foroperating the production system shown in FIG. 1;

[0014]FIG. 6 is an exemplary architecture block diagram of a softwarecode segment that implements the real-time production system economicdispatch system shown in FIG. 3; and

[0015]FIG. 7 is an exemplary data flow block diagram of an overview ofsoftware code segment that implements real-time production systemeconomic dispatch system shown in FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

[0016]FIG. 1 is a schematic diagram of an exemplary production system 10that includes at least one production facility 12 that includes areceiving system 14 for supplying a first resource 16, such as coal, tofacility 12. In the exemplary embodiment, facility 12 is a coal-firedpower generation plant that receives coals from a plurality of sources.Each facility 12 may have different operating characteristics from eachother facility 12, including, but not limited to, facility productioncapability, efficiency, and availability. Each facility 12 also includesa production output 18 that is coupled to a transmission system 20. Inthe exemplary embodiment, outputs 18 are transmission wires that connecteach facility 12 a transmission system, or grid 20. In an alternativeembodiment, output 18 may be a pipeline for transporting liquid orgaseous produced goods. In another alternative embodiment, each output18 may be a transport system for transporting discrete produced goodsthrough a vehicle-based transport system.

[0017] Each facility 12 includes a plurality of second resources 22,which controls and utilizes the received first resources 16 to produce aproduction output. For example, in the exemplary embodiment, secondaryresources 22 include, but are not limited to, boilers, pumps,condensers, conveyors, a distributed control systems (DCS) 24, andelectrical switchgear. Resources 22 are monitored and controlled fromDCS 24, which receives inputs from resources 22, provides indicationsfor facility operators, and transmits commands to resources 22 tocontrol the operation thereof. In the exemplary embodiment, each DCS 24is communicatively coupled through a network 26 to a central computer28. In one embodiment, network 26 is communicatively coupled to at leastone remote client for monitoring, modifying and controlling theoperation of system 10.

[0018] In operation, each facility receives first resource 16, which isutilized by second resources 24 to produce a production output. Theproduction process is monitored and controlled by DCS 24 and may useadditional resources. A product is then transmitted through output 18 toa transmission system that carries the product away from facility 12into a stream of commerce. By-products and any waste produced within theproduction process are also monitored and controlled by DCS 24.Pollutants released during the production process are monitored by DCS24 or other associated systems (not shown) to account for their release.

[0019]FIG. 2 is a detailed schematic of an exemplary facility 12 thatmay be used with system 10 (shown in FIG. 1). In the exemplaryembodiment, facility 12 produces electrical energy from combusting afuel, for example, coal. Alternatively, facility 12 may be used toproduce other products utilizing other resources. Coal sources 102 routecoal to coal yard 104, wherein the coal is sorted in a storage area orcoal yard 104, and is segregated into coal piles 106, 108, and 110 ofsimilar quality for storage. Coal quality is determined based on acoal's heat content, usually expressed in BTUs per Ibm., quantity of ashand pollutant precursors found within the coal, such as, sulfur,arsenic, lead, and mercury, and based on the quantity of combustion orpollution control aiding constituents, such as sodium within the coal.Coal is transferred from piles 106, 108, and 110 to a blending facility112 at a rate that forms a fuel blend including a predeterminedconcentration of coal from each coal pile 106, 108, and 110. The blendedcoal is then transported to a plant area 114 within facility 12 andstored for immediate use in one or more coal bunkers 116. Known coalbunkers 116 are sized to store between one half day to one and a halfdays supply of coal for the production process when the process isoperating at full capability. Each facility 12 may have a differentbunker storage capability depending on the design of each facility 12.Plant area 114 includes a furnace/boiler portion 120 that includes aplurality of burners 122 spaced about the periphery of the boiler atdifferent vertical elevations. Each elevation burner 122 is coupled to amill 124 that crushes the coal and mixes the pulverized coal withpreheated air, and to a coal feeder 126 that supplies coal to mill 124at a predetermined rate. Furnace/boiler 120 circulates exhaust gases andflyash through backpasses and ductwork 128, which also provides variousmeasured outputs associated with the boiler operation. In addition,exhaust from furnace 120 may contain pollutants, such as, sulphurousoxides (SO_(x)) and nitrous oxides (NO_(x)) and as such, a stack monitorsensor 132 may be included in ductwork 128 for monitoring output offacility 12.

[0020] Heat released by the combustion of coal in furnace/boiler 120heats water in tubes extending around the periphery of furnace/boiler120 to generate steam. The steam collects in a drum 134 and is directedto a steam turbine 136 through steam pipe 138. The steam is channeledthrough turbine 136 wherein work is extracted form the steam to turn ashaft 140 coupled to an electric generator 142. Exhausted steam exitsturbine 136 and enters a condenser 144 wherein the steam is condensedback to water and then is returned to furnace/boiler 120 to repeat thecycle. Cooling water from an external source (not shown) is circulatedthough condenser 144 to remove heat from the steam for condensation,then returned to the source.

[0021] In operation, coal from piles 106, 108, and 110 is blended basedon anticipated facility load and desired operating characteristics ofthe production process. For example, if a load forecast requests that afacility 12 operate at maximum capability, a higher heat content coalblend may be supplied to facility 12 to achieve a maximum output.Typically, a higher heat content fuel costs more than a lower heatcontent fuel, and therefore when a load forecast does not requirefacility 12 to operate at maximum capability, a lesser quality fuel maypermit more cost effective operation of facility 12. Typically, coal istransported to bunkers 116 at a rate faster than the coal is combustedin furnace 120. Bunkers 116 are filled and the coal transport system isshut down while coal in the bunkers is used to supply furnace 120. Oncedeposited in bunkers 116, the coal blend must be supplied to furnace 120to deplete it. Consequently, there is a time lag associated with a needto change the fuel blend, and a time period before which the blend willreach furnace 120. Accordingly, a load forecast needs to be anticipatoryof changing conditions that may necessitate facility 12 to operate atmaximum capability to compensate for such time lags.

[0022] In the exemplary embodiment, furnace 120 is a “tangentiallyfired” boiler. However, it should be noted that facility 12 is notlimited to a tangentially-fired boiler 1120, but rather other boilersnot utilizing tangential firing could be accommodated, such as, but notlimited to, a wall-fired boiler or a cyclone boiler. In atangentially-fired boiler a fireball may be created proximate to burners122. More specifically, by varying the coal/air feed rates to burners122, the fireball may be raised or lowered in the furnace. The placementof the fireball may have an effect on the efficiency, or heat rate, theNOx concentration level, and the output of unburned carbon (Loss onIgnition (LOI)). Accordingly, controlling each of these parameters mayaffect overall heat rate and incremental cost curves for system 10.

[0023]FIG. 3 is a simplified block diagram of a real-time productionsystem economic dispatch system 300 including a server system 312, and aplurality of client sub-systems, also referred to as client systems 314,communicatively coupled to server system 312. As used herein, real-timerefers to outcomes occurring at a substantially short period after achange in the inputs affecting the outcome. The period is the amount oftime between each iteration of a regularly repeated task. Such repeatedtasks are called periodic tasks. The time period is a design parameterof the real-time system that may be selected based on the importance ofthe outcome and/or the capability of the system implementing processingof the inputs to generate the outcome. In the exemplary embodiment,calculations are updated in real-time with a periodicity of one minute.In one embodiment, client systems 314 are computers including a webbrowser, such that server system 312 is accessible to client systems 314via the Internet. Client systems 314 are interconnected to the Internetthrough many interfaces including a network, such as a local areanetwork (LAN) or a wide area network (WAN), dial-in-connections, cablemodems and special high-speed ISDN lines. Client systems 314 could beany device capable of interconnecting to the Internet including aweb-based phone, personal digital assistant (PDA), or other web-basedconnectable equipment. A database server 316 is connected to a database320 containing information regarding a plurality of matters, asdescribed below in greater detail. In one embodiment, centralizeddatabase 320 is stored on server system 312 and can be accessed bypotential users at one of client systems 314 by logging onto serversystem 312 through one of client systems 314. In an alternativeembodiment database 320 is stored remotely from server system 312 andmay be non-centralized.

[0024]FIG. 4 is an expanded version block diagram of an exemplaryarchitecture of a server system 400 of the real-time production systemeconomic dispatch system 300 shown in FIG. 3. Components in system 400,that are identical to components of system 300 (shown in FIG. 3), areidentified in FIG. 4 using the same reference numerals as used in FIG.3. System 400 includes server system 312 and client systems 314. Serversystem 312 further includes database server 316, an application server424, a web server 426, a fax server 428, a directory server 430, and amail server 432. A disk storage unit 434 is coupled to database server316 and directory server 430. Servers 316, 424, 426, 428, 430, and 432are communicatively coupled in a local area network (LAN) 436. Inaddition, a system administrator's workstation 438, a user workstation440, and a supervisor's workstation 442 are coupled to LAN 436.Alternatively, workstations 438, 440, and 442 are coupled to LAN 436 viaan Internet link or are connected through an Intranet.

[0025] Each workstation, 438, 440, and 442 is a personal computer havinga web browser. As used herein, the term computer is not limited to justthose integrated circuits referred to in the art as processors, butbroadly refers to computers, processors, microcontrollers,microcomputers, programmable logic controllers, application specificintegrated circuits, and other programmable circuits. Although thefunctions performed at the workstations typically are illustrated asbeing performed at respective workstations 438, 440, and 442, suchfunctions can be performed at one of many personal computers coupled toLAN 436. Workstations 438, 440, and 442 are illustrated as beingassociated with separate functions only to facilitate an understandingof the different types of functions that can be performed by individualshaving access to LAN 436. In an exemplary embodiment, client system 314includes workstation 346 which can be used by an internal user or adesignated outside user to review real-time production system economicdispatch system 300 information relating to the connected system.

[0026] Server system 312 is configured to be communicatively coupled tovarious individuals, including dispatchers 444 and to third parties,e.g., designated outside users, 446 via an ISP Internet connection 448.The communication in the example embodiment is illustrated as beingperformed via the Internet, however, any other wide area network (WAN)type communication can be utilized in other embodiments, i.e., thesystems and processes are not limited to being practiced via theInternet. In addition, and rather than WAN 450, local area network 436could be used in place of WAN 450.

[0027] In the example embodiment, any authorized individual having aworkstation 454 can access real-time production system economic dispatchsystem 300. At least one of the client systems includes a managerworkstation 456 located at a remote location. Workstations 454 and 456are personal computers having a web browser. Also, workstations 454 and456 are configured to communicate with server system 312. Furthermore,fax server 428 communicates with remotely located client systems,including a client system 456 via a telephone link. Fax server 428 isconfigured to communicate with other client systems 438, 440, and 442 aswell.

[0028]FIG. 5 is a flow chart illustrating an exemplary method 500 foroperating a production system, such as system 10 (shown in FIG. 1). Theproduction system includes one or more production facilities whoseoperation is coordinated by a computer system that executes a softwarecode segment based on inputs received from each facility. Morespecifically, the computer system receives 502, in real-time, cost datarelating to a first resource used by the facility to produce an output.In the exemplary embodiment, the first resource data is received 502using a stand-alone commercial software product, such as, Coalogic®,commercially available from General Electric Company, Fremont Hills,Calif. In an alternative embodiment, the first resource data is received502 from a pre-existing distributed control system (DCS) (shown inFIG. 1) through a custom interface.

[0029] The first resource may be received at each facility at a ratesubstantially equal to a rate the resource is used at the facility. Forexample, when the first resource is a fuel resource, such as natural gasthe first resource may be received at the facility at approximately thesame rata the resource is used at the facility. Alternatively, the firstresource may be received at each facility at a rate in excess of theutilization rate, such as, for example, when the first resource is afuel resource such, as coal.

[0030] Cost data received 502 includes, but is not limited to receivingfuel quality data, such as, fuel heat content, pollutant content, andby-product content, fuel transport costs, and/or fuel handling costs.The fuel quality is a factor in determining the output capability of theproduction facility. The fuel system transit time may be a measure ofshort-term coal quality, in that coal already deposited in the bunkersmust be utilized in the furnace at the current rate of utilizationbefore coal of higher quality can be supplied to the furnace. As such,typically, there is a time lag between when a decision is made toimprove the coal quality and when the higher quality coal reaches thefurnace. Such a determination is based on several factors including, forexample, blending time, pipeline transit time, and bunker transit time.Blending time includes time allocated for moving coal from eachsegregated pile to the blending facility. Pipeline considers the timethe coal spends in the classifier or crusher and time on the conveyorbelt. Typically, blending time and conveyor transit times are relativelyshort in relation to bunker transit time. For example, bunker transittime may be on the order of tens of hours.

[0031] The software code segment receives 504, in real-time, cost datafor a second resource used by each facility to produce the desiredoutput. In the exemplary embodiment, the second resource includes knowncoal-fired power plant components communicatively coupled to a DCS thatmonitors the operation of the power plant components and reportscomponent health anomalies that may impact the overall operation of thesystem. Cost data for power plant components is based on several factorsincluding facility heat rate, facility auxiliary load, productionequipment availability, a time period required to make productionequipment available, a cost to make production equipment available, andproduction system fixed and variable costs attributable to the facility.The software code segment includes standard and/or custom modulesprogrammed to interface with online distributed control systems (DCS)such that the heat rate may be calculated automatically and on acontinuous basis for input into the production optimization software.For example, a predictor module may predict a future output capabilityof the facility based on facility ramp rate, the time period required tomake production equipment available, fuel system transit time, an amountof fuel stored at the facility, and the current fuel usage rate or a“what-if” fuel usage rate.

[0032] The software code segment determines 506, in real-time anautomated incremental cost curve for the system based on a level ofproduction for each facility and the received resource cost data. Thesoftware code segment also determines 508 a production output target foreach production facility to achieve an optimum production system outputbased on the real-time incremental cost curves.

[0033]FIG. 6 is an exemplary architecture block diagram of a softwarecode segment 600 that implements real-time production system economicdispatch system 300 shown in FIG. 3. Software code segment 600 is aclient-server product, with a standalone Graphical User Interface (GUI)601 that provides a user-friendly interface to dispatch system 300. Morespecifically, GUI 601 interfaces with existing dispatch managementsoftware, and transmits accurate real-time data to improve generationdecisions. GUI 601 includes integrated Fuel Tracking Technology, whichallows accurate monitoring of track as they move through the yard to theboiler. Furthermore, the fuel tracking technology also enables GUI 601to perform facility performance calculations, such that, accuratereal-time and projected heat rate calculations may be performed at anyload, based on detailed on-line heat balance modeling.

[0034] Real-time production system economic dispatch system 300 includesa central computer system 28 that executes software code segment 600.Furthermore, computer system 28 is programmed to determine, for eachproduction facility in the production system, real-time economicdispatch control curves, real-time fuel quality, fuel cost, heat ratecurves, and generation data for dispatch decisions, short and long termprojections of fuel quality, fuel cost, heat rate, and generation datautilizing a “what-if” projector tool, and pertinent information for useduring emergency response situations, such as when fuel loadingequipment breaks down.

[0035] A data storage device 602 may include hard disk magnetic oroptical storage units, as well as CD-ROM drives and/or flash memory.Data storage device 602 includes databases used in the processing oftransactions between various components of economic dispatch system 300,including an event manager 604 that is programmed to exchange data withat least one data storage device 602. In the exemplary embodimentdatabase software such as SQL Server, manufactured by MicrosoftCorporation, is used to create and manage these databases.

[0036] Event Manager 604 coordinates data flow between a solver module606, a fuel tracking module 608, a plant object module 610, and a blendadvisor module 612, and a broker module 614. Broker module 614 isprogrammed to exchange data with an optimizer module 616, an advisormodule 618, a heat rate and generation cost module 620, and a reportermodule 622. A GUI agent 624 may be communicatively coupled to optimizermodule 616, advisor module 618, heat rate and generation cost module 620and reporter module 622. Reporter module 622 is communicatively coupledto a network 626 and is programmed to upload reporter module output toserver 602. GUI agent 624 is also communicatively coupled to a remoteclient 601 through a secure HTTP tunnel using extended networkmanagement protocol (ENMP).

[0037]FIG. 7 is an exemplary data flow block diagram 700 of an overviewof software code segment 600 that implements real-time production systemeconomic dispatch system 300 (shown in FIG. 3). Economic dispatch system300 includes data receiving modules, such as, for example, a fueltracking module 702 and a process component tracking module 704. Fueltracking module 702 receives fuel and yard data 706 from each facility12 in production system 10 (shown in FIG. 1), such as, for example, fuelquality, fuel storage quantity, fuel feed rate capability, and fuelsupply equipment health, such as crusher and conveyor availability. Fueltracking module 702 receives data 706 in real-time from on-linemonitoring systems and/or periodically from manual input sources and/orperiodic reports from automated systems. From data 706, fuel trackingmodule 702 determines real-time fuel cost and quality data by monitoringfuel flow from coal yard 104 to bunkers 116 and maintaining blendingconcentrations of fuel in bunkers 116.

[0038] Process component tracking module 704 receives real-time fuelquality and fuel property data 708 from fuel tracking module 702 andreal-time plant component operational data 710 from on-line DCS 24and/or stand alone monitoring systems and manual data input at eachfacility to supply detailed component and production process systemmodels executing within module 704. The models monitor real-time data710 across a load range of production facility 12 range, facility loadcapacity and fuel quality to generate real-time facility heat ratecurves.

[0039] Real time fuel cost and fuel quality data 714 from fuel trackingmodule 702 and real-time heat rate curves 716 from process componenttracking module 704 from facilities 12 are transmitted to a dispatchdecision module 718. Additionally, module 718 receives fuel data 720from a facility economics database 722, including information pertainingto fuel types, fuel properties and fuel costs. Module 718 also receivesfacility data and operations and maintenance costs 724 from a user inputmodule 726. Module 726 may include corporate financing, support andmiscellaneous costs attributable to each facility but not availablethrough facility systems or databases. For example, such data mayinclude facility specific data, emissions cost factors, and fixed andvariable costs.

[0040] Dispatch decision module 718 integrates real-time fuel qualityand cost, real-time heat curves, and facility plant operation andmaintenance costs to generate real-time dispatch cost curves that may beused to facilitate optimizing operation of system 10, such that asystem-wide least cost dispatch strategy is facilitated based onindividual facility economics, facility optimization, and pro-activedispatch decision-making. Dispatch decision module 718 generatesdispatch cost curves and related cost data 728 to a facility generationmanagement module 730. Data 728 may include Incremental Cost ControlCurves, which illustrate the incremental cost of facility operations asa function of load or output for each facility within production system10, Fuel Heating Values, which are the real-time mass-averaged heatingvalues for fuel entering furnace/boiler 120 for each facility 12; FuelCosts, which are the real-time mass-averaged cost for fuel enteringfurnace/boiler 120 for each facility 12, Heat Rate Curves, generated asare real-time heat rate at any load based on detailed on-line heat ratemodels and component data, and Maximum MW Producible, which indicates amaximum output producible by each facility and is calculated based onthe mass-averaged heating value entering furnace/boiler 120, thecalculated heat rate, and the calculated maximum feed rate for each mill124 based on the current fuel running through mill 124. Thesecalculations are updated periodically, for example, every minute and caneither be transmitted to DCS 24 or to a plant historian, whereindispatch control software can access them, or transmitted directly tothe dispatch control software via WAN 450.

[0041] Dispatch cost curves and related cost data 728 may also be usedto improve Automatic Generation Control (AGC) and general dispatchdecisions. AGC represents short-term corrections in the load to begenerated for facilities units that have been placed in that mode ofoperation. AGC corrections are typically made on the order of everysecond.

[0042] Economic dispatch system 300 is configurable to provide input for“what if” scenarios through its What-If Projector functionality. TheWhat If Projector can be used to determine and display short and longterm projections for fuel quality, costs and operational data for futuretime periods, such as, up to the next twenty-four hours. For eachfacility in production system 10, economic dispatch system 300 providesthe ability to run short-term projections of the upcoming fuel quality,fuel cost, and heat rate. Using this tool, the user will be able to seevalues for any fuel quality parameter tracked by economic dispatchsystem 300, including cost, as well as projected heat rate in bothgraphical and tabular format over the time required for the currentbunker contents to empty based on an entered load profile. Long-termprojections are similar to short-term projections but extend theprojection up to 24 hours in the future, using a modeling of a fuelloading. This tool can be used to estimate the impacts of loading anypotential fuel source into any of the facilities' bunkers. In theexemplary embodiment, the user is provided with multiple means to enterprojected load profiles, fuel sources to be loaded, and timing for theloading.

[0043] Economic dispatch system 300 provides as output from theprojection functionality, Projected Fuel Properties, which are themass-averaged properties for the fuel entering furnace/boiler 120 foreach facility projected over the desired time period, Projected FuelCost, which is the mass-averaged cost for the fuel enteringfurnace/boiler 120 for each facility projected over the time period, andProjected Heat Rate, which is averaged heat rate based on detailedon-line heat rate modeling over the time period.

[0044] Economic dispatch system 300 is configurable to provide input foremergency response scenarios through its Emergency Response Datafunctionality. The Emergency Response Data functionality provides a userwith important information for use during emergency response situations,such as, component breakdown that affects fueling the facility or theoutput capability of the facility. Emergency response data providesinformation about how much fuel is remaining in each bunker, how long itwill last at the current or a projected facility load, how quickly achange in fuel quality can be made, and how much output each facilitycan assume. The information that is calculated and displayed in a GUIclient display includes Bunker Maximum Power Potential, which is themaximum power that the facility can achieve under the current conditionsand available fuel in bunkers 116; Bunker Response Time, which is thenumber of hours that will elapse before a new fuel loaded immediatelyinto the bunker would reach the burners, such as would occur if greateroutput is desired from a unit since it specifies how long it would bebefore a premium fuel could reach the burners; Bunker Burn Time, whichis the number of hours the system could run at the maximum capabilitybefore new fuel must be added to the bunker.

[0045] While the present invention is described with reference to asystem of coal-fired power plants, numerous other applications arecontemplated. It is contemplated that the present invention may beapplied to any system of production facilities, including a facilitiesthat produce fluid outputs, such as, refineries and midstream liquidsfacilities, and facilities that produce discrete product outputs, suchas, factories.

[0046] The above-described real-time production system economic dispatchsystem is cost-effective and highly reliable system for dispatchingproduction system resources. More specifically, the methods and systemsdescribed herein facilitate determining facility output capabilitiesduring various operating conditions and the real-time costs associatedwith those operations. In addition, the above-described methods andsystems facilitate providing increased data to system operators forjudging the health and emergency response capability of the system. As aresult, the methods and systems described herein facilitate reducingoperating costs in a cost-effective and reliable manner.

[0047] Exemplary embodiments of real-time production system economicdispatch systems are described above in detail. The systems are notlimited to the specific embodiments described herein, but rather,components of each system may be utilized independently and separatelyfrom other components described herein. Each system component can alsobe used in combination with other system components.

[0048] While the invention has been described in terms of variousspecific embodiments, those skilled in the art will recognize that theinvention can be practiced with modification within the spirit and scopeof the claims.

What is claimed is:
 1. A method for operating a production system thatincludes a plurality of production facilities, said method comprising:receiving, in real-time, for each facility, cost data for a firstresource used by each respective facility to produce an output;receiving, in real-time, for each facility, cost data for a secondresource used by each respective facility to produce the output;determining, in real-time, an automated incremental cost curve for thesystem based on a level of production of each facility and the receivedresource cost data; and determining a production output target for eachproduction facility to achieve an optimum production system output basedon the real-time incremental cost curves.
 2. A method in accordance withclaim 1 further comprising receiving a first resource at each facilityat a rate that is substantially equal to a rate the resource is used atthe respective facility.
 3. A method in accordance with claim 1 furthercomprising storing an amount of the first resource at the facility inexcess of an amount of the first resource used at the respectivefacility.
 4. A method in accordance with claim 1 wherein receiving costdata for a first resource comprises receiving at least one of fuelquality data, fuel transport costs, and fuel handling costs from eachrespective facility.
 5. A method in accordance with claim 4 whereinreceiving at least one of fuel quality data comprises receiving at leastone of fuel heat content, pollutant content, and byproduct content fromeach respective facility.
 6. A method in accordance with claim 4 furthercomprising determining a production facility output capability based onfuel quality of fuel supplied to each respective facility.
 7. A methodin accordance with claim 6 wherein determining a production facilityoutput capability comprises determining a fuel system transit time foreach respective facility.
 8. A method in accordance with claim 7 whereindetermining a fuel system transit time comprises determining at leastone of a blending time, a pipeline transit time, and a bunker transittime for each respective facility.
 9. A method in accordance with claim1 wherein receiving cost data for a second resource comprises receivingat least one of a facility heat rate, a facility auxiliary load, aproduction equipment availability, a time period required to makeproduction equipment available, a cost to make production equipmentavailable, and production system fixed and variable costs attributableto each respective facility.
 10. A method in accordance with claim 9wherein receiving a facility heat rate comprises receiving a facilityheat rate from an online distributed control system (DCS) at eachrespective facility.
 11. A method in accordance with claim 1 furthercomprising predicting a future output capability of a facility based onat least one of a facility ramp rate, a time period required to makeproduction equipment available and a fuel system transit time.
 12. Amethod in accordance with claim 1 further comprising determining afacility output capability based on an amount of fuel stored at thefacility and at least one of a current fuel usage rate of the facilityand a second fuel usage rate wherein the second usage rate is differentthan the current usage rate.
 13. A method in accordance with claim 1wherein determining, in real-time; an automated incremental cost curvefurther comprises determining, in real-time, the incremental cost ofproduction system operations as a function of load for each facilitywithin a utility system.
 14. A method in accordance with claim 1 furthercomprising determining a fuel heating value in real time wherein thefuel heating value includes the mass-averaged heating value for the fuelentering the boiler for each respective facility.
 15. A method inaccordance with claim 1 further comprising determining a fuel cost inreal time wherein fuel cost is a mass-averaged cost for the fuelentering the boiler for each respective facility,
 16. A method inaccordance with claim 1 further comprising determining a facility heatrate curve wherein real-time heat rate at any load is based on detailedon-line heat rate data.
 17. A production system for producing an outputcomprising: at least one production facility comprising a first resourcereceiving system, and a second resource configured to control andutilize said first resource in a production process; and a computersystem programmed to determine, in real-time, an incremental cost ofsaid first resource at each respective facility based on a level ofproduction of said facility.
 18. A production system in accordance withclaim 17 wherein said software code segment comprises an event managerprogrammed to exchange data with at least one of an SQL server, a solvermodule, a fuel tracking module, a plant object module, a blend advisormodule, and a broker module.
 19. A production system in accordance withclaim 18 wherein said broker module is programmed to exchange data withat least one of an optimizer module, an advisor module, a heat rate andgeneration cost module and a reporter module.
 20. A production system inaccordance with claim 18 further comprising a GUI agent communicativelycoupled to at least one of the optimizer module, the advisor module, theheat rate and generation cost module and the reporter module.
 21. Aproduction system in accordance with claim 20 wherein said reportermodule is communicatively coupled to a network and programmed to uploadreporter module output to a server.
 22. A production system inaccordance with claim 20 wherein said GUI agent is communicativelycoupled to a remote client through a secure HTTP tunnel using extendednetwork management protocol (ENMP).
 23. A software code segment forcontrolling a computer to determine, in real-time, an incremental costof operating a plurality of production facilities based on a firstresource input to each respective facility and a second resourceutilization of the first resource at each respective facility, saidincremental cost based on a level of production of each said respectivefacility, said segment including: a fuel tracking module programmed fortracking at least one of real-time fuel cost, real-time fuel flow, andreal time fuel quality for each respective facility; a process componenttracking module for modeling facility components to generate real-timeheat rate curves for each respective facility; and a dispatch decisionmodule programmed to receive inputs from at least one of said fueltracking module, said process component tracking module, and saiddispatch decision module configured to generate real-time systemdispatch cost curves.
 24. A software code segment in accordance withclaim 23 wherein said dispatch decision module is further configured toreceive data from a facility economics database.
 25. A software codesegment in accordance with claim 24 wherein said facility economicsdatabase includes at least one of fuel type data, fuel property data,and fuel cost data.
 26. A software code segment in accordance with claim23 wherein said dispatch decision module is further configured toreceive data from a user input module.
 27. A software code segment inaccordance with claim 26 wherein said user input module includes unitspecific data, emission cost factors, and fixed and variable costsattributable to each respective facility.
 28. A software code segment inaccordance with claim 23 programmed to generate dispatch commands for anautomatic generation control, (AGC) system at each respective facility.29. A software code segment in accordance with claim 23 programmed togenerate dispatch recommendations for each respective facility thatfacilitates optimizing the overall heat rate for said plurality ofproduction facilities.
 30. A software code segment in accordance withclaim 23 programmed to generate dispatch recommendations for eachfacility that facilitates optimizing responding to a breakdown at leastone of said plurality of production facilities.